US20090291219A1 - Fluoropolymer solutions, coatings and coated articles - Google Patents
Fluoropolymer solutions, coatings and coated articles Download PDFInfo
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- US20090291219A1 US20090291219A1 US12/124,566 US12456608A US2009291219A1 US 20090291219 A1 US20090291219 A1 US 20090291219A1 US 12456608 A US12456608 A US 12456608A US 2009291219 A1 US2009291219 A1 US 2009291219A1
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- monomer units
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- pentafluoropropylene
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- 238000000576 coating method Methods 0.000 title claims description 23
- 229920002313 fluoropolymer Polymers 0.000 title claims description 9
- 239000004811 fluoropolymer Substances 0.000 title claims description 9
- 229920001577 copolymer Polymers 0.000 claims abstract description 47
- DMUPYMORYHFFCT-UHFFFAOYSA-N 1,2,3,3,3-pentafluoroprop-1-ene Chemical group FC=C(F)C(F)(F)F DMUPYMORYHFFCT-UHFFFAOYSA-N 0.000 claims abstract description 43
- 238000000034 method Methods 0.000 claims abstract description 31
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 claims abstract description 15
- 239000000178 monomer Substances 0.000 claims description 40
- 239000002904 solvent Substances 0.000 claims description 33
- ZQBFAOFFOQMSGJ-UHFFFAOYSA-N hexafluorobenzene Chemical group FC1=C(F)C(F)=C(F)C(F)=C1F ZQBFAOFFOQMSGJ-UHFFFAOYSA-N 0.000 claims description 26
- 239000011248 coating agent Substances 0.000 claims description 22
- 238000001704 evaporation Methods 0.000 claims description 4
- 238000003618 dip coating Methods 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 229920000642 polymer Polymers 0.000 description 40
- 239000000243 solution Substances 0.000 description 38
- 238000006116 polymerization reaction Methods 0.000 description 12
- 238000002844 melting Methods 0.000 description 10
- 230000008018 melting Effects 0.000 description 10
- 238000000113 differential scanning calorimetry Methods 0.000 description 9
- 230000004927 fusion Effects 0.000 description 8
- 239000000203 mixture Substances 0.000 description 7
- 238000003756 stirring Methods 0.000 description 7
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 6
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 6
- 150000002978 peroxides Chemical class 0.000 description 6
- 239000007788 liquid Substances 0.000 description 5
- 238000004293 19F NMR spectroscopy Methods 0.000 description 4
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 4
- 238000007334 copolymerization reaction Methods 0.000 description 4
- 230000003247 decreasing effect Effects 0.000 description 4
- 239000011521 glass Substances 0.000 description 4
- 230000010354 integration Effects 0.000 description 4
- 239000006193 liquid solution Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- HCDGVLDPFQMKDK-UHFFFAOYSA-N hexafluoropropylene Chemical group FC(F)=C(F)C(F)(F)F HCDGVLDPFQMKDK-UHFFFAOYSA-N 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- RIQRGMUSBYGDBL-UHFFFAOYSA-N 1,1,1,2,2,3,4,5,5,5-decafluoropentane Chemical compound FC(F)(F)C(F)C(F)C(F)(F)C(F)(F)F RIQRGMUSBYGDBL-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical class [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- DTQVDTLACAAQTR-UHFFFAOYSA-N Trifluoroacetic acid Chemical compound OC(=O)C(F)(F)F DTQVDTLACAAQTR-UHFFFAOYSA-N 0.000 description 2
- -1 accelerators Substances 0.000 description 2
- 239000012190 activator Substances 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- JHIVVAPYMSGYDF-UHFFFAOYSA-N cyclohexanone Chemical compound O=C1CCCCC1 JHIVVAPYMSGYDF-UHFFFAOYSA-N 0.000 description 2
- 239000008367 deionised water Substances 0.000 description 2
- 229910021641 deionized water Inorganic materials 0.000 description 2
- ZQMIGQNCOMNODD-UHFFFAOYSA-N diacetyl peroxide Chemical compound CC(=O)OOC(C)=O ZQMIGQNCOMNODD-UHFFFAOYSA-N 0.000 description 2
- 238000004090 dissolution Methods 0.000 description 2
- 239000003995 emulsifying agent Substances 0.000 description 2
- 150000002432 hydroperoxides Chemical class 0.000 description 2
- 238000010348 incorporation Methods 0.000 description 2
- 239000012442 inert solvent Substances 0.000 description 2
- 239000003999 initiator Substances 0.000 description 2
- 239000003607 modifier Substances 0.000 description 2
- 150000001451 organic peroxides Chemical class 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- WRXCBRHBHGNNQA-UHFFFAOYSA-N (2,4-dichlorobenzoyl) 2,4-dichlorobenzenecarboperoxoate Chemical compound ClC1=CC(Cl)=CC=C1C(=O)OOC(=O)C1=CC=C(Cl)C=C1Cl WRXCBRHBHGNNQA-UHFFFAOYSA-N 0.000 description 1
- JMYZLRSSLFFUQN-UHFFFAOYSA-N (2-chlorobenzoyl) 2-chlorobenzenecarboperoxoate Chemical compound ClC1=CC=CC=C1C(=O)OOC(=O)C1=CC=CC=C1Cl JMYZLRSSLFFUQN-UHFFFAOYSA-N 0.000 description 1
- TXGPGHBYAPBDAG-UHFFFAOYSA-N 1,1,2,2,3,3-hexafluoro-4,4-bis(trifluoromethyl)cyclobutane Chemical compound FC(F)(F)C1(C(F)(F)F)C(F)(F)C(F)(F)C1(F)F TXGPGHBYAPBDAG-UHFFFAOYSA-N 0.000 description 1
- BLTXWCKMNMYXEA-UHFFFAOYSA-N 1,1,2-trifluoro-2-(trifluoromethoxy)ethene Chemical compound FC(F)=C(F)OC(F)(F)F BLTXWCKMNMYXEA-UHFFFAOYSA-N 0.000 description 1
- WUMVZXWBOFOYAW-UHFFFAOYSA-N 1,2,3,3,4,4,4-heptafluoro-1-(1,2,3,3,4,4,4-heptafluorobut-1-enoxy)but-1-ene Chemical compound FC(F)(F)C(F)(F)C(F)=C(F)OC(F)=C(F)C(F)(F)C(F)(F)F WUMVZXWBOFOYAW-UHFFFAOYSA-N 0.000 description 1
- BZPCMSSQHRAJCC-UHFFFAOYSA-N 1,2,3,3,4,4,5,5,5-nonafluoro-1-(1,2,3,3,4,4,5,5,5-nonafluoropent-1-enoxy)pent-1-ene Chemical compound FC(F)(F)C(F)(F)C(F)(F)C(F)=C(F)OC(F)=C(F)C(F)(F)C(F)(F)C(F)(F)F BZPCMSSQHRAJCC-UHFFFAOYSA-N 0.000 description 1
- USPWUOFNOTUBAD-UHFFFAOYSA-N 1,2,3,4,5-pentafluoro-6-(trifluoromethyl)benzene Chemical compound FC1=C(F)C(F)=C(C(F)(F)F)C(F)=C1F USPWUOFNOTUBAD-UHFFFAOYSA-N 0.000 description 1
- WACNXHCZHTVBJM-UHFFFAOYSA-N 1,2,3,4,5-pentafluorobenzene Chemical compound FC1=CC(F)=C(F)C(F)=C1F WACNXHCZHTVBJM-UHFFFAOYSA-N 0.000 description 1
- UTQNKKSJPHTPBS-UHFFFAOYSA-N 2,2,2-trichloroethanone Chemical group ClC(Cl)(Cl)[C]=O UTQNKKSJPHTPBS-UHFFFAOYSA-N 0.000 description 1
- LRMSQVBRUNSOJL-UHFFFAOYSA-N 2,2,3,3,3-pentafluoropropanoic acid Chemical compound OC(=O)C(F)(F)C(F)(F)F LRMSQVBRUNSOJL-UHFFFAOYSA-N 0.000 description 1
- JDQSSIORVLOESA-UHFFFAOYSA-N 2,2-difluoro-4,5-bis(trifluoromethyl)-1,3-dioxole Chemical compound FC(F)(F)C1=C(C(F)(F)F)OC(F)(F)O1 JDQSSIORVLOESA-UHFFFAOYSA-N 0.000 description 1
- HZBKQEWFXAGSNH-UHFFFAOYSA-N 2,3,4,5,6-pentafluoro-2-(1,1,2,2,3,3,3-heptafluoropropyl)pyran Chemical compound FC1=C(F)C(F)=C(F)C(F)(C(F)(F)C(F)(F)C(F)(F)F)O1 HZBKQEWFXAGSNH-UHFFFAOYSA-N 0.000 description 1
- CVIPNXAABKWPHN-UHFFFAOYSA-N 2-(1-ethenoxy-1,1,2,3,3,3-hexafluoropropan-2-yl)oxy-1,1,2,2-tetrafluoroethanesulfonyl fluoride Chemical compound C=COC(F)(F)C(F)(C(F)(F)F)OC(F)(F)C(F)(F)S(F)(=O)=O CVIPNXAABKWPHN-UHFFFAOYSA-N 0.000 description 1
- OZAIFHULBGXAKX-UHFFFAOYSA-N 2-(2-cyanopropan-2-yldiazenyl)-2-methylpropanenitrile Chemical compound N#CC(C)(C)N=NC(C)(C)C#N OZAIFHULBGXAKX-UHFFFAOYSA-N 0.000 description 1
- MKTOIPPVFPJEQO-UHFFFAOYSA-N 4-(3-carboxypropanoylperoxy)-4-oxobutanoic acid Chemical compound OC(=O)CCC(=O)OOC(=O)CCC(O)=O MKTOIPPVFPJEQO-UHFFFAOYSA-N 0.000 description 1
- CDVQWSAOXQJKAR-UHFFFAOYSA-N 4-cyano-2,2-dimethylpentanoic acid Chemical compound CC(C#N)CC(C)(C(=O)O)C CDVQWSAOXQJKAR-UHFFFAOYSA-N 0.000 description 1
- SDUVARGIUSLKPP-UHFFFAOYSA-N 4-cyanoheptanoic acid Chemical compound CCCC(C#N)CCC(O)=O SDUVARGIUSLKPP-UHFFFAOYSA-N 0.000 description 1
- XRUKRHLZDVJJSX-UHFFFAOYSA-N 4-cyanopentanoic acid Chemical compound N#CC(C)CCC(O)=O XRUKRHLZDVJJSX-UHFFFAOYSA-N 0.000 description 1
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 1
- 239000004342 Benzoyl peroxide Substances 0.000 description 1
- OMPJBNCRMGITSC-UHFFFAOYSA-N Benzoylperoxide Chemical compound C=1C=CC=CC=1C(=O)OOC(=O)C1=CC=CC=C1 OMPJBNCRMGITSC-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical class [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical class S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- YIVJZNGAASQVEM-UHFFFAOYSA-N Lauroyl peroxide Chemical compound CCCCCCCCCCCC(=O)OOC(=O)CCCCCCCCCCC YIVJZNGAASQVEM-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical class [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- DWAQJAXMDSEUJJ-UHFFFAOYSA-M Sodium bisulfite Chemical compound [Na+].OS([O-])=O DWAQJAXMDSEUJJ-UHFFFAOYSA-M 0.000 description 1
- 239000004133 Sodium thiosulphate Substances 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 150000001335 aliphatic alkanes Chemical class 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- ROOXNKNUYICQNP-UHFFFAOYSA-N ammonium peroxydisulfate Substances [NH4+].[NH4+].[O-]S(=O)(=O)OOS([O-])(=O)=O ROOXNKNUYICQNP-UHFFFAOYSA-N 0.000 description 1
- VAZSKTXWXKYQJF-UHFFFAOYSA-N ammonium persulfate Chemical compound [NH4+].[NH4+].[O-]S(=O)OOS([O-])=O VAZSKTXWXKYQJF-UHFFFAOYSA-N 0.000 description 1
- 229910001870 ammonium persulfate Inorganic materials 0.000 description 1
- 150000003863 ammonium salts Chemical class 0.000 description 1
- 239000012736 aqueous medium Substances 0.000 description 1
- 239000007900 aqueous suspension Substances 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- YOALFLHFSFEMLP-UHFFFAOYSA-N azane;2,2,3,3,4,4,5,5,6,6,7,7,8,8,8-pentadecafluorooctanoic acid Chemical compound [NH4+].[O-]C(=O)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)F YOALFLHFSFEMLP-UHFFFAOYSA-N 0.000 description 1
- ZJRXSAYFZMGQFP-UHFFFAOYSA-N barium peroxide Chemical compound [Ba+2].[O-][O-] ZJRXSAYFZMGQFP-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 235000019400 benzoyl peroxide Nutrition 0.000 description 1
- 229910021538 borax Inorganic materials 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 239000000872 buffer Substances 0.000 description 1
- 239000006172 buffering agent Substances 0.000 description 1
- 235000011089 carbon dioxide Nutrition 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 229920001688 coating polymer Polymers 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Chemical class 0.000 description 1
- YQHLDYVWEZKEOX-UHFFFAOYSA-N cumene hydroperoxide Chemical compound OOC(C)(C)C1=CC=CC=C1 YQHLDYVWEZKEOX-UHFFFAOYSA-N 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 238000001938 differential scanning calorimetry curve Methods 0.000 description 1
- WBZKQQHYRPRKNJ-UHFFFAOYSA-L disulfite Chemical compound [O-]S(=O)S([O-])(=O)=O WBZKQQHYRPRKNJ-UHFFFAOYSA-L 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000004446 fluoropolymer coating Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910000078 germane Inorganic materials 0.000 description 1
- 229910000856 hastalloy Inorganic materials 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- BCCOBQSFUDVTJQ-UHFFFAOYSA-N octafluorocyclobutane Chemical compound FC1(F)C(F)(F)C(F)(F)C1(F)F BCCOBQSFUDVTJQ-UHFFFAOYSA-N 0.000 description 1
- 235000019407 octafluorocyclobutane Nutrition 0.000 description 1
- YPJUNDFVDDCYIH-UHFFFAOYSA-N perfluorobutyric acid Chemical compound OC(=O)C(F)(F)C(F)(F)C(F)(F)F YPJUNDFVDDCYIH-UHFFFAOYSA-N 0.000 description 1
- SNGREZUHAYWORS-UHFFFAOYSA-N perfluorooctanoic acid Chemical compound OC(=O)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)F SNGREZUHAYWORS-UHFFFAOYSA-N 0.000 description 1
- 125000000864 peroxy group Chemical group O(O*)* 0.000 description 1
- 125000005342 perphosphate group Chemical group 0.000 description 1
- 229920003223 poly(pyromellitimide-1,4-diphenyl ether) Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 239000007870 radical polymerization initiator Substances 0.000 description 1
- 238000010526 radical polymerization reaction Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Chemical class 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 235000010267 sodium hydrogen sulphite Nutrition 0.000 description 1
- 239000004289 sodium hydrogen sulphite Substances 0.000 description 1
- 235000010262 sodium metabisulphite Nutrition 0.000 description 1
- 239000004296 sodium metabisulphite Substances 0.000 description 1
- NVIFVTYDZMXWGX-UHFFFAOYSA-N sodium metaborate Chemical compound [Na+].[O-]B=O NVIFVTYDZMXWGX-UHFFFAOYSA-N 0.000 description 1
- PFUVRDFDKPNGAV-UHFFFAOYSA-N sodium peroxide Chemical compound [Na+].[Na+].[O-][O-] PFUVRDFDKPNGAV-UHFFFAOYSA-N 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 235000019345 sodium thiosulphate Nutrition 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 150000004763 sulfides Chemical class 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- GJBRNHKUVLOCEB-UHFFFAOYSA-N tert-butyl benzenecarboperoxoate Chemical compound CC(C)(C)OOC(=O)C1=CC=CC=C1 GJBRNHKUVLOCEB-UHFFFAOYSA-N 0.000 description 1
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert‐butyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 1
- DHCDFWKWKRSZHF-UHFFFAOYSA-L thiosulfate(2-) Chemical compound [O-]S([S-])(=O)=O DHCDFWKWKRSZHF-UHFFFAOYSA-L 0.000 description 1
- YNJBWRMUSHSURL-UHFFFAOYSA-N trichloroacetic acid Chemical compound OC(=O)C(Cl)(Cl)Cl YNJBWRMUSHSURL-UHFFFAOYSA-N 0.000 description 1
- 238000013022 venting Methods 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
- C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/02—Halogenated hydrocarbons
- C08K5/03—Halogenated hydrocarbons aromatic, e.g. C6H5-CH2-Cl
Definitions
- the present invention is directed to coatable solutions of copolymers of 1,2,3,3,3-pentafluoropropylene and tetrafluoroethylene, processes for preparing coated articles, films, and coated articles.
- Sianesi et al. U.S. Pat. No. 3,350,373 discloses copolymers of 1,2,3,3,3-pentafluoropropylene and tetrafluoroethylene, a method for preparing them, and a process for melt forming shaped articles.
- Sianesi's polymers are crystalline polymers having 1,2,3,3,3-pentafluoropropylene comonomer concentrations of less than 20 mole percent.
- Amorphous fluoropolymers include copolymers of TFE with perfluoromethylvinylether, perfluoroethylvinylether, perfluoropropylene (HFP), perfluorodimethyldioxole, perfluoro-2-(2-fluorosulfonylethoxy) propyl vinyl ether, and others.
- Solvents disclosed include fluorinated alkanes, fluorinated alkenes, fluorinated sulfides, hexafluorobenzene and others.
- Amorphous fluoropolymers are characterized by having no melting transition with a heat of fusion greater than 1 J/g as determined by differential scanning calorimetry (DSC).
- the HFP copolymers are ca. 48 mole percent HFP.
- Tuminello et al. U.S. Pat. No. 6,767,626, discloses a method for protection of stone by preparing coated stone surfaces using substantially amorphous copolymers of hexafluoropropylene and tetrafluoroethylene.
- the present invention provides a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- the present invention further provides a method for preparing a coated article, the method comprising contacting the surface of an article having a surface with a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene; and, evaporating the solvent to produce a coated article.
- the present invention further provides a coated article comprising an article having a surface and a coating disposed upon the surface, the coating comprising an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene, the coating being characterized by a thickness of ⁇ 10 micrometers.
- FIG. 1 show the differential scanning calorimetry scans for polymers prepared in the Examples.
- amorphous refers to a polymer having no melting endotherm having a heat of fusion greater than 2 J/g as determined by differential scanning calorimetry (DSC). Amorphous copolymers of TFE with 1,2,3,3,3-pentafluoropropylene have not previously been reported.
- the term “soluble” when referring to a polymer means that the polymer combines in a liquid solvent to form a clear, homogeneous liquid solution or gel at room temperature.
- the manner by which the room temperature liquid solution or gel is prepared is not germane to the definition.
- a polymer observed to be insoluble at room temperature may be combined with the solvent and the combination heated with stirring to cause the polymer to enter solution at an elevated temperature, forming a clear homogeneous liquid.
- the polymer is considered soluble in the solvent “Clear and homogeneous” are determined by simple visual inspection of the specimen in a clear glass vessel.
- copolymer refers to a copolymer comprising 20 to 50 mole percent of 1,2,3,3,3-pentafluoropropylene and 50 to 80 mole percent of TFE.
- the term further encompasses terpolymers or other multi-polymers wherein an additional one or more monomer units derived from olefinic monomers are included in the copolymer.
- the total of all the one or more additional monomer units is preferably not more than 10 mole percent.
- a copolymer comprising 20 to 50 mole percent of 1,2,3,3,3-pentafluoropropylene this means that the copolymer comprises 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene upon copolymerization with TFE.
- the copolymer is described as “comprising 50-80 mole percent of TFE,” what is meant is that the copolymer comprises 50-80 mole percent of monomer units derived from TFE upon copolymerization with 1,2,3,3,3-pentafluoropropylene. Similar descriptions are used herein in the same manner.
- the copolymers disclosed herein are characterized by novel solubility characteristics which afford a high and unusual utility.
- Tetrafluoroethylene homopolymers are well-known to be virtually insoluble and intractable, partially because of high crystallinity and partially because of high molecular weight.
- Fluorinated copolymers of tetrafluoroethylene and other olefinic fluoromonomers such as hexafluoropropylene and perfluoropropylvinyl ether are insoluble at comonomer (i.e., non TFE) content below about 20 mole percent.
- Hrivnak et al. disclose that at comonomer content of around 25 mole percent up to ca. 50 mole percent copolymers known in the art become substantially amorphous, and exhibit moderate to good solubility in a wide range of fluorinated solvents, as well as some other solvents such as hydrocarbons and supercritical CO 2 .
- the copolymers disclosed herein exhibit a considerable decrease in crystallinity with increasing comonomer content. No melting endotherm having a heat of fusion greater than 2 J/g was observed in differential scanning calorimetry (DSC) of 1,2,3,3,3-pentafluoropropylene copolymers with TFE at comonomer content of 20-50 mole percent.
- solubility of the polymers disclosed herein is limited to highly fluorinated aromatic hydrocarbon solvents. Solubility in other fluorinated solvents is not observed. Some polymer swelling is sometimes observed, but a liquid solution is not formed.
- a coating of a few micrometers up to about 100 micrometers can be applied to a surface from solution in, e.g., hexafluorobenzene, to protect a surface.
- the coating is ⁇ 10 micrometers in thickness.
- the surface can then be exposed to an environment in which non-aromatic fluorinated solvents are employed, for example in cleaning, without significant degradation of the protective coating.
- multi-layer fluoropolymer coatings or laminates of fluoropolymers can be fabricated by applying a first layer of a coating to a substrate from a hexafluorobenzene solution of an embodiment of the polymer, followed by drying. A second layer of the coating of a second polymer, the second polymer not being, is then applied from a solution thereof whereof the solvent is not a fluorinated aromatic hydrocarbon so that the first layer of the coating is undisturbed by the application of the second layer.
- the present invention provides, in one embodiment, a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- the copolymer comprises 25 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- the copolymer comprises 30 to 45 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- the copolymers can be prepared according to methods known in the art.
- the composition of the copolymer can be varied by varying the composition of the monomeric mixture and the temperature at which the polymerization reaction is conducted. Generally, higher reaction temperatures favor incorporation of a higher proportion of 1,2,3,3,3-pentafluoropropylene units into the copolymer.
- 1,2,3,3,3-pentafluoropropylene is less reactive in copolymerization than TFE under a given set of conditions.
- the polymerization mixture preferably has a higher content of the 1, 2,3,3,3-pentafluoropropylene than that which is desired in the final product.
- the monomer concentration of 1,2,3,3,3-pentafluoropropylene preferably ranges from about 50 mole percent to about 85 mole percent, and the concentration of TFE ranges from about 15 mole percent to about 50 mole percent.
- the fluorinated copolymers can be prepared at temperatures ranging from about ⁇ 30° C. to about 200° C., under pressures varying from atmospheric to above 300 atm., and in the presence of free-radical polymerization initiators.
- the preferred reaction temperature and pressure will depend, however, on the type of catalytic system employed.
- the polymerization can be carried out in an aqueous medium if desired, including polymerization in an aqueous suspension, aqueous emulsion, polymerization in bulk or in solution.
- inert solvents that do not contain C—H bonds are preferred.
- Suitable inert solvents include perhalogenated or perfluorinated compounds that are liquid under operating conditions, such as perfluorocyclobutane, perfluorodimethylcyclobutane, perfluoropropylpyrane, or tetrafluorodichloroethane.
- Suitable initiators include perhalogenated or perfluorinated peroxy compounds such as peroxides of trichloroacetic acid, heptafluorobutyric acid, trifluoroacetic acid, pentafluoropropionic acid, or perfluorocaprylic acid.
- peroxides of the ⁇ -hydroperfluoro acids having the general formula H(CF 2 ) n —COOH wherein n ranges from 1 to 8 can be used.
- suitable initiators include water-soluble organic peroxides, diperoxides or hydroperoxides, or inorganic peroxides.
- suitable inorganic peroxides include ammonium or alkaline and alkaline earth metals persulphates, perphosphates, perborates, barium peroxide, sodium peroxide, or hydrogen peroxide.
- Suitable organic peroxides include benzoyl peroxide, p.
- chlorobenzoyl peroxide 2,4-dichlorobenzoyl peroxide, acetyl peroxide, trichloroacetyl, peroxide, lauroyl peroxide, succinyl peroxide, di-t.-butyl peroxide, peroxides and hydroperoxides of methylethylketone and of cyclohexanone, t-butyl perbenzoate, t-butyl-hydroperoxide, or cumyl hydroperoxide.
- Aliphatic azo-compounds can also be employed, such as alpha,alpha′azobis(isobutyronitrile), alpha,alpha′-azobis(alpha-methyl-gamma-carboxybutyronitrile), alpha,alpha′-azobis(alpha, gamma-dimethyl-gamma-carboxy-valeronitrile), alpha,alpha′-azobis(alpha-propyl-gamma-carboxybutyronitrile).
- ingredients that can be used in aqueous polymerization include emulsifying agents, activators, accelerators, modifiers, buffers, etc.
- Emulsifying agents include alkali, alkaline earth or ammonium salts of perhalogenated or ⁇ -hydroperhalogenated fatty acids having 6 to 20 carbons atoms.
- Suitable activators include sodium bisulphite, metabisulphite and thiosulphate or, in general, any water-soluble reducing substance.
- the accelerators include salts of metals occurring in various valence states, such as soluble salts of iron, copper, silver, etc.
- the modifiers include mercaptans or the aliphatic halocarbons which may be employed to regulate the polymerization reaction.
- Suitable buffering agents include sodium or potassium mono- or bi-phosphates or mixtures thereof, sodium metaborate, or borax.
- the copolymerization reaction When the copolymerization reaction is carried out in water, it is preferred to operate at a temperature ranging from about 5° C. to 100° C. and more preferably at a temperature ranging from about 10° C. to 90° C. under a pressure ranging from atmospheric to 200 atm.
- a solution can be formed by combining the amorphous copolymer after drying with a fluoroaromatic solvent while stirring, at a copolymer concentration of 1% to 20% by weight of the total weight of the solution.
- the degree of solubility depends upon the content in the polymer of the 1,2,3,3,3-polypropylene comonomer, with greater comonomer content corresponding to higher solubility.
- the polymer concentration is 5-15% by weight of the total weight of the solution.
- Dissolution is normally achieved at room temperature by stirring for about 30 minutes. It may be beneficial to heat the combination to about 60° C. while stirring to effect dissolution. In such case, when cooled, the solution so formed may form a gel rather than a pourable liquid.
- Suitable fluoroaromatic solvents include but are not limited to hexafluorobenzene, pentafluorobenzene, and octafluorotoluene. Hexafluorobenzene is preferred.
- Another embodiment of the present invention is a method for preparing a coated article, the method comprising providing an article having a surface for coating, and contacting the surface with a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene; and, evaporating the solvent to produce a coated article.
- the solution comprises 1-20% by weight of the amorphous copolymer, preferably 5-15% by weight, based on the total weight of the solution.
- the viscosity of the solution can be adjusted to meet the requirements of the method by which the solution is applied to the surface.
- the solution is applied to the surface of the article at room temperature.
- the solution is applied to the surface at an elevated temperature.
- the solution is applied to the surface at a temperature below room temperature.
- the manner in which the surface is contacted with the solution is not limited.
- One method is to use a doctor blade to spread the solution on a flat surface at a uniform thickness.
- Other suitable methods include spray coating, dip coating, brushing or rolling, and other such methods as are commonly employed in the art for coating the surface of articles with polymer solutions.
- a coated article comprising an article having a surface and a coating disposed upon the surface, the coating comprising an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- the coating has a thickness of 10 micrometers or less.
- melt extrusion of polymers is commonly used in the art to produce films of a thickness of ca. 25 micrometers or greater. Although thinner melt extruded films are known, they are not typical. Melt coating is generally limited to the coating of flat surfaces. Solution coating is not limited to surface of any particular shape, and is particularly well-suited for preparation of coating that are less than or equal to 10 micrometers in thickness.
- the coated articles have surfaces that are protected from contamination, and from a wide variety of solvents because of the limited solubility of the coating polymer.
- the coated articles can be disposed to receive the application of additional layers from solution that contains a solvent other than a fluoroaromatic solvent.
- the white residue was suspended in 500 ml of deionized water, stirred for 30 minutes, filtered again, and dried on the filter by pulling air through. The resulting polymeric residue was further dried in vacuum oven at 50° C. for 12 hours. 14.8 g of white spongy polymer was obtained after drying.
- the 19 F NMR of the melted polymer (at 160° C.) showed four broad peaks which upon integration showed that the polymer contained 27 mole percent of 1,2,3,3,3-pentafluoropropylene.
- 0.5 g of polymer powder was placed between sheets of Kapton® Polyimide Film to form a sandwich.
- the sandwich so formed was placed between the platens of a hydraulic press (Pasadena Hydraulics) and held at contact pressure for 5 minutes at 120° C. After the 5 minute pre-heat, the force on the press was increased to 15,000 lbs. and held for 3 minutes. Then the press was cooled to 60° C. and the pressure was released. A film approximately 75 micrometers in thickness) was obtained.
- a second specimen was prepared under identical conditions except that the temperature was 135° C. and the resulting film was approximately 65 micrometers thick. In both cases, the films were clear, homogeneous, ductile and tough.
- Example 1 The materials and procedures of Example 1 were repeated except that 56 g of 1,2,3,3,3-pentafluoropropylene and 9 g of TFE were used. During the polymerization the pressure decreased from 336 psi to 318 psi. 5.6 g of dry polymer were obtained. The 19 F NMR of the melted polymer (at 115° C.) showed four broad peaks which upon integration showed that the polymer contained 36.5 mole percent of 1,2,3,3,3-pentafluoropropylene.
- Example 1 The materials and procedures of Example 1 were repeated except that 46 g of 1,2,3,3,3-pentafluoropropylene and 31 g of TFE were used and the autoclave was heated to 80° C. for ten hours. During the polymerization the pressure decreased from 530 psi to 367 psi. 29.3 g of dry polymer were obtained. The 19 F NMR of the melted polymer (at 115° C.) showed four broad peaks which upon integration showed that the polymer contained 20 mole percent of 1,2,3,3,3-pentafluoropropylene.
- the polymer so prepared did not dissolve in hexafluorobenzene at room temperature to any significant extent, but at 60° C. 200 mg dissolved fairly easily in 2 mL of hexafluorobenzene to give a clear solution. Upon cooling the solution down to room temperature it became a gel.
- a 7-10 mg of specimen was crimped in a standard sealed aluminum DSC pan.
- the specimen was placed in a TA Instruments model Q2000 DSC and heated rapidly (ca. 20 C.°/min) to a temperature in the range of 260-320° C. and held at temperature for 3 minutes. followed by cooling to ca. 0° C.
- the specimen was then reheated to the maximum temperature of 260-320° C. at 10° C./min rate with the aid of a mechanical cooler for temperature control, and data was recorded.
- the location of the melting endotherm, where one existed, was determined visually, and the heat of fusion determined from the weight normalized integral of the melting endotherm.
- Example 2 The procedures of Example 1 were repeated except that 49 g of 1,2,3,3,3-pentafluoropropylene and 26 g of TFE were used and the autoclave was heated to 80° C. for ten hours. During the polymerization the pressure decreased from 465 psi to 445 psi. 8.6 g of dry polymer were obtained. A DSC curve obtained between ca. 0° C. and 300° C. exhibited a broad shallow endotherm with a heat of fusion of ca. 6 J/g indicating a small amount of crystallinity. The 19 F NMR of the melted polymer (at 115° C.) showed four broad peaks which upon integration showed that the polymer contained 17.5 mole percent of 1,2,3,3,3-pentafluoropropylene.
- the polymer did not dissolve in hexafluorobenzene at room temperature. 100 mg of the polymer were suspended in 4 mL hexafluorobenzene (4 mL) and heated to 60° C. a clear solution was not obtained even on prolonged (4 hours) stirring.
- FIG. 1 shows the DSC results obtained according to the method described above. A well defined endotherm was identified corresponding to a melting transition at 177.66° C., and a heat of fusion of ca 10 J/g.
- Example 1 The materials and procedures of Example 1 were replicated except that the ratio of 1,2,3,3,3-pentafluoropropylene to TFE was slightly higher to give a polymer containing 30 mol-% of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- FIG. 2 shows the DSC results obtained. No melting endotherm could be discerned.
- Example 1 The materials and procedures of Example 1 were replicated except that the ratio of 1,2,3,3,3-pentafluoropropylene to TFE was slightly higher to give a polymer containing 40 mol-% of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- FIG. 3 shows the DSC results obtained.
- a very small melting endotherm associated with a crystalline melting point of 83° C. might be an artifact.
- the associated heat of fusion was 0.7 J/g.
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Abstract
Provided are coatable solutions of copolymers of 1,2,3,3,3-pentafluoropropylene and tetrafluoroethylene, processes for preparing coated articles, films, and coated articles.
Description
- The present invention is directed to coatable solutions of copolymers of 1,2,3,3,3-pentafluoropropylene and tetrafluoroethylene, processes for preparing coated articles, films, and coated articles.
- Sianesi et al., U.S. Pat. No. 3,350,373 discloses copolymers of 1,2,3,3,3-pentafluoropropylene and tetrafluoroethylene, a method for preparing them, and a process for melt forming shaped articles. Sianesi's polymers are crystalline polymers having 1,2,3,3,3-pentafluoropropylene comonomer concentrations of less than 20 mole percent.
- Hrivnak et al., U.S. Pat. No. 6,248,823, discloses solvents for so-called amorphous fluoropolymers. Amorphous fluoropolymers include copolymers of TFE with perfluoromethylvinylether, perfluoroethylvinylether, perfluoropropylene (HFP), perfluorodimethyldioxole, perfluoro-2-(2-fluorosulfonylethoxy) propyl vinyl ether, and others. Solvents disclosed include fluorinated alkanes, fluorinated alkenes, fluorinated sulfides, hexafluorobenzene and others. Amorphous fluoropolymers are characterized by having no melting transition with a heat of fusion greater than 1 J/g as determined by differential scanning calorimetry (DSC). The HFP copolymers are ca. 48 mole percent HFP.
- Tuminello et al., U.S. Pat. No. 6,767,626, discloses a method for protection of stone by preparing coated stone surfaces using substantially amorphous copolymers of hexafluoropropylene and tetrafluoroethylene.
- The present invention provides a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- The present invention further provides a method for preparing a coated article, the method comprising contacting the surface of an article having a surface with a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene; and, evaporating the solvent to produce a coated article.
- The present invention further provides a coated article comprising an article having a surface and a coating disposed upon the surface, the coating comprising an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene, the coating being characterized by a thickness of <10 micrometers.
- FIG. 1—show the differential scanning calorimetry scans for polymers prepared in the Examples.
- As used herein, the term “amorphous” refers to a polymer having no melting endotherm having a heat of fusion greater than 2 J/g as determined by differential scanning calorimetry (DSC). Amorphous copolymers of TFE with 1,2,3,3,3-pentafluoropropylene have not previously been reported.
- As used herein, the term “soluble” when referring to a polymer means that the polymer combines in a liquid solvent to form a clear, homogeneous liquid solution or gel at room temperature. The manner by which the room temperature liquid solution or gel is prepared is not germane to the definition. Thus, a polymer observed to be insoluble at room temperature, may be combined with the solvent and the combination heated with stirring to cause the polymer to enter solution at an elevated temperature, forming a clear homogeneous liquid. Just so long as the solution so produced when cooled to room temperature remains clear and homogeneous, either as a liquid solution or gel, the polymer is considered soluble in the solvent “Clear and homogeneous” are determined by simple visual inspection of the specimen in a clear glass vessel.
- As used herein, the term “copolymer” refers to a copolymer comprising 20 to 50 mole percent of 1,2,3,3,3-pentafluoropropylene and 50 to 80 mole percent of TFE. The term further encompasses terpolymers or other multi-polymers wherein an additional one or more monomer units derived from olefinic monomers are included in the copolymer. However, the total of all the one or more additional monomer units is preferably not more than 10 mole percent.
- When a copolymer is described herein as “comprising 20 to 50 mole percent of 1,2,3,3,3-pentafluoropropylene this means that the copolymer comprises 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene upon copolymerization with TFE. Similarly, when the copolymer is described as “comprising 50-80 mole percent of TFE,” what is meant is that the copolymer comprises 50-80 mole percent of monomer units derived from TFE upon copolymerization with 1,2,3,3,3-pentafluoropropylene. Similar descriptions are used herein in the same manner.
- The copolymers disclosed herein are characterized by novel solubility characteristics which afford a high and unusual utility. Tetrafluoroethylene homopolymers are well-known to be virtually insoluble and intractable, partially because of high crystallinity and partially because of high molecular weight. Fluorinated copolymers of tetrafluoroethylene and other olefinic fluoromonomers such as hexafluoropropylene and perfluoropropylvinyl ether are insoluble at comonomer (i.e., non TFE) content below about 20 mole percent.
- Hrivnak et al. disclose that at comonomer content of around 25 mole percent up to ca. 50 mole percent copolymers known in the art become substantially amorphous, and exhibit moderate to good solubility in a wide range of fluorinated solvents, as well as some other solvents such as hydrocarbons and supercritical CO2. The copolymers disclosed herein exhibit a considerable decrease in crystallinity with increasing comonomer content. No melting endotherm having a heat of fusion greater than 2 J/g was observed in differential scanning calorimetry (DSC) of 1,2,3,3,3-pentafluoropropylene copolymers with TFE at comonomer content of 20-50 mole percent.
- However, the present inventors have found that, surprisingly, solubility of the polymers disclosed herein is limited to highly fluorinated aromatic hydrocarbon solvents. Solubility in other fluorinated solvents is not observed. Some polymer swelling is sometimes observed, but a liquid solution is not formed.
- The novel solubility behavior gives rise to high utility. For example, a coating of a few micrometers up to about 100 micrometers can be applied to a surface from solution in, e.g., hexafluorobenzene, to protect a surface. Preferably the coating is ≦10 micrometers in thickness. The surface can then be exposed to an environment in which non-aromatic fluorinated solvents are employed, for example in cleaning, without significant degradation of the protective coating.
- As a further example, multi-layer fluoropolymer coatings or laminates of fluoropolymers can be fabricated by applying a first layer of a coating to a substrate from a hexafluorobenzene solution of an embodiment of the polymer, followed by drying. A second layer of the coating of a second polymer, the second polymer not being, is then applied from a solution thereof whereof the solvent is not a fluorinated aromatic hydrocarbon so that the first layer of the coating is undisturbed by the application of the second layer.
- Accordingly, the present invention provides, in one embodiment, a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene. Preferably the copolymer comprises 25 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene. Most preferably the copolymer comprises 30 to 45 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
- The copolymers can be prepared according to methods known in the art. The composition of the copolymer can be varied by varying the composition of the monomeric mixture and the temperature at which the polymerization reaction is conducted. Generally, higher reaction temperatures favor incorporation of a higher proportion of 1,2,3,3,3-pentafluoropropylene units into the copolymer.
- It is known that 1,2,3,3,3-pentafluoropropylene is less reactive in copolymerization than TFE under a given set of conditions. In order to achieve the desirably high 1,2,3,3,3-pentafluoropropylene incorporation into the copolymer, the polymerization mixture preferably has a higher content of the 1, 2,3,3,3-pentafluoropropylene than that which is desired in the final product. Thus, the monomer concentration of 1,2,3,3,3-pentafluoropropylene preferably ranges from about 50 mole percent to about 85 mole percent, and the concentration of TFE ranges from about 15 mole percent to about 50 mole percent.
- The fluorinated copolymers can be prepared at temperatures ranging from about −30° C. to about 200° C., under pressures varying from atmospheric to above 300 atm., and in the presence of free-radical polymerization initiators. The preferred reaction temperature and pressure will depend, however, on the type of catalytic system employed. The polymerization can be carried out in an aqueous medium if desired, including polymerization in an aqueous suspension, aqueous emulsion, polymerization in bulk or in solution.
- When polymerization is carried out in non-aqueous solution, inert solvents that do not contain C—H bonds are preferred. Suitable inert solvents include perhalogenated or perfluorinated compounds that are liquid under operating conditions, such as perfluorocyclobutane, perfluorodimethylcyclobutane, perfluoropropylpyrane, or tetrafluorodichloroethane. Suitable initiators include perhalogenated or perfluorinated peroxy compounds such as peroxides of trichloroacetic acid, heptafluorobutyric acid, trifluoroacetic acid, pentafluoropropionic acid, or perfluorocaprylic acid. In addition, peroxides of the ω-hydroperfluoro acids having the general formula H(CF2)n—COOH wherein n ranges from 1 to 8 can be used.
- In aqueous polymerization, suitable initiators include water-soluble organic peroxides, diperoxides or hydroperoxides, or inorganic peroxides. Suitable inorganic peroxides include ammonium or alkaline and alkaline earth metals persulphates, perphosphates, perborates, barium peroxide, sodium peroxide, or hydrogen peroxide. Suitable organic peroxides include benzoyl peroxide, p. chlorobenzoyl peroxide, 2,4-dichlorobenzoyl peroxide, acetyl peroxide, trichloroacetyl, peroxide, lauroyl peroxide, succinyl peroxide, di-t.-butyl peroxide, peroxides and hydroperoxides of methylethylketone and of cyclohexanone, t-butyl perbenzoate, t-butyl-hydroperoxide, or cumyl hydroperoxide. Aliphatic azo-compounds can also be employed, such as alpha,alpha′azobis(isobutyronitrile), alpha,alpha′-azobis(alpha-methyl-gamma-carboxybutyronitrile), alpha,alpha′-azobis(alpha, gamma-dimethyl-gamma-carboxy-valeronitrile), alpha,alpha′-azobis(alpha-propyl-gamma-carboxybutyronitrile).
- Other ingredients that can be used in aqueous polymerization include emulsifying agents, activators, accelerators, modifiers, buffers, etc. Emulsifying agents include alkali, alkaline earth or ammonium salts of perhalogenated or ω-hydroperhalogenated fatty acids having 6 to 20 carbons atoms. Suitable activators include sodium bisulphite, metabisulphite and thiosulphate or, in general, any water-soluble reducing substance. The accelerators include salts of metals occurring in various valence states, such as soluble salts of iron, copper, silver, etc. The modifiers include mercaptans or the aliphatic halocarbons which may be employed to regulate the polymerization reaction. Suitable buffering agents include sodium or potassium mono- or bi-phosphates or mixtures thereof, sodium metaborate, or borax.
- When the copolymerization reaction is carried out in water, it is preferred to operate at a temperature ranging from about 5° C. to 100° C. and more preferably at a temperature ranging from about 10° C. to 90° C. under a pressure ranging from atmospheric to 200 atm.
- A solution can be formed by combining the amorphous copolymer after drying with a fluoroaromatic solvent while stirring, at a copolymer concentration of 1% to 20% by weight of the total weight of the solution. The degree of solubility depends upon the content in the polymer of the 1,2,3,3,3-polypropylene comonomer, with greater comonomer content corresponding to higher solubility. Preferably the polymer concentration is 5-15% by weight of the total weight of the solution. Dissolution is normally achieved at room temperature by stirring for about 30 minutes. It may be beneficial to heat the combination to about 60° C. while stirring to effect dissolution. In such case, when cooled, the solution so formed may form a gel rather than a pourable liquid.
- Suitable fluoroaromatic solvents include but are not limited to hexafluorobenzene, pentafluorobenzene, and octafluorotoluene. Hexafluorobenzene is preferred.
- Another embodiment of the present invention is a method for preparing a coated article, the method comprising providing an article having a surface for coating, and contacting the surface with a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene; and, evaporating the solvent to produce a coated article. The solution comprises 1-20% by weight of the amorphous copolymer, preferably 5-15% by weight, based on the total weight of the solution.
- To obtain a spreadable liquid suitable for making a coating, the viscosity of the solution can be adjusted to meet the requirements of the method by which the solution is applied to the surface. In one embodiment the solution is applied to the surface of the article at room temperature. In another embodiment, the solution is applied to the surface at an elevated temperature. In still another embodiment, the solution is applied to the surface at a temperature below room temperature.
- The manner in which the surface is contacted with the solution is not limited. One method is to use a doctor blade to spread the solution on a flat surface at a uniform thickness. Other suitable methods include spray coating, dip coating, brushing or rolling, and other such methods as are commonly employed in the art for coating the surface of articles with polymer solutions.
- In a further embodiment of the present invention there is provided a coated article, comprising an article having a surface and a coating disposed upon the surface, the coating comprising an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene. In preferred embodiments the coating has a thickness of 10 micrometers or less.
- Generally, because of difficulty handling and melt strength melt extrusion of polymers is commonly used in the art to produce films of a thickness of ca. 25 micrometers or greater. Although thinner melt extruded films are known, they are not typical. Melt coating is generally limited to the coating of flat surfaces. Solution coating is not limited to surface of any particular shape, and is particularly well-suited for preparation of coating that are less than or equal to 10 micrometers in thickness.
- The coated articles have surfaces that are protected from contamination, and from a wide variety of solvents because of the limited solubility of the coating polymer. In that regard, the coated articles can be disposed to receive the application of additional layers from solution that contains a solvent other than a fluoroaromatic solvent.
- 5 g of a 20% solution of ammonium perfluorooctanoate was diluted to 100 mL with deionized water and combined with 0.20 g of ammonium persulfate (Sigma-Aldrich) (0.20 g) in a
Hastelloy® C 400 cm3 autoclave. The autoclave was chilled to 5° C., evacuated, pressured with nitrogen to 400 psi and vented off. The pressuring and venting were repeated and a vacuum was then applied to the interior of the autoclave. The autoclave was then chilled to −30° C. 56 g of 1,2,3,3,3-pentafluoropropylene prepared in the manner described by Sianesi et al., op.cit. was condensed in followed by pressuring with 14 g of TFE) and sealing. The sealed autoclave was heated to 70° C. and held for 16 hours. During that time the pressure gradually decreased from 377 psi to 321 psi. The autoclave was cooled to room temperature, and the excess gases were vented off. A clear aqueous solution was removed from the reactor and frozen in dry ice for at least 4 hours. The frozen solution was then allowed to thaw and then filtered through #1 Whatman filter paper. The white residue was suspended in 500 ml of deionized water, stirred for 30 minutes, filtered again, and dried on the filter by pulling air through. The resulting polymeric residue was further dried in vacuum oven at 50° C. for 12 hours. 14.8 g of white spongy polymer was obtained after drying. The 19F NMR of the melted polymer (at 160° C.) showed four broad peaks which upon integration showed that the polymer contained 27 mole percent of 1,2,3,3,3-pentafluoropropylene. - 180 mg of the thus prepared polymer was dissolved in 3.3 g of hexafluorobenzene (Aldrich) by stirring at room temperature for 30 minutes to give a clear, homogeneous 5 wt.-% solution. The thus prepared solution was cast on a regular glass plate using a 0.005 in. (127.5 micrometer) Doctor's blade. After evaporation of the solvent a coating 1-2 micrometers thick remained on the glass plate.
- Attempts to prepare similar solutions using other solvents were unsuccessful. The mixtures made were neither clear nor homogeneous. Solvents employed were dichloromethane (OmniSolve), toluene (OmniSolv), acetone (EMD), Vertrel XF (2,3-dihydrodecafluoropentane—DuPont), Novec HFE 7500 (3-ethoxy-1,1,1,2,3,4,4,5,5,6,6,6-dodecafluoro-2-trifluoromethyl-hexane—Synquest).
- 0.5 g of polymer powder was placed between sheets of Kapton® Polyimide Film to form a sandwich. The sandwich so formed was placed between the platens of a hydraulic press (Pasadena Hydraulics) and held at contact pressure for 5 minutes at 120° C. After the 5 minute pre-heat, the force on the press was increased to 15,000 lbs. and held for 3 minutes. Then the press was cooled to 60° C. and the pressure was released. A film approximately 75 micrometers in thickness) was obtained. A second specimen was prepared under identical conditions except that the temperature was 135° C. and the resulting film was approximately 65 micrometers thick. In both cases, the films were clear, homogeneous, ductile and tough.
- The materials and procedures of Example 1 were repeated except that 56 g of 1,2,3,3,3-pentafluoropropylene and 9 g of TFE were used. During the polymerization the pressure decreased from 336 psi to 318 psi. 5.6 g of dry polymer were obtained. The 19F NMR of the melted polymer (at 115° C.) showed four broad peaks which upon integration showed that the polymer contained 36.5 mole percent of 1,2,3,3,3-pentafluoropropylene.
- 500 mg of the thus prepared polymer was dissolved in 3.3 g of hexafluorobenzene by stirring at room temperature for 30 minutes to give a clear, homogeneous 13 wt-% solution.
- Attempts to prepare similar solutions using other solvents were unsuccessful. The mixtures made were neither clear nor homogeneous. Solvents employed were dichloromethane (OmniSolve), toluene (OmniSolv), acetone (EMD), Vertrel XF (2,3-dihydrodecafluoropentane—DuPont), Novec HFE 7500 (3-ethoxy-1,1,1,2,3,4,4,5,5,6,6,6-dodecafluoro-2-trifluoromethyl-hexane—Synquest). The last two fluorinated solvents made the polymer look like an oil, which sticks to the glass walls of the vessel, but did not form a solution.
- The materials and procedures of Example 1 were repeated except that 46 g of 1,2,3,3,3-pentafluoropropylene and 31 g of TFE were used and the autoclave was heated to 80° C. for ten hours. During the polymerization the pressure decreased from 530 psi to 367 psi. 29.3 g of dry polymer were obtained. The 19F NMR of the melted polymer (at 115° C.) showed four broad peaks which upon integration showed that the polymer contained 20 mole percent of 1,2,3,3,3-pentafluoropropylene.
- The polymer so prepared did not dissolve in hexafluorobenzene at room temperature to any significant extent, but at 60° C. 200 mg dissolved fairly easily in 2 mL of hexafluorobenzene to give a clear solution. Upon cooling the solution down to room temperature it became a gel.
- In order to identify a melting endotherm and determine the heat of fusion, the following procedure was followed. A 7-10 mg of specimen was crimped in a standard sealed aluminum DSC pan. The specimen was placed in a TA Instruments model Q2000 DSC and heated rapidly (ca. 20 C.°/min) to a temperature in the range of 260-320° C. and held at temperature for 3 minutes. followed by cooling to ca. 0° C. The specimen was then reheated to the maximum temperature of 260-320° C. at 10° C./min rate with the aid of a mechanical cooler for temperature control, and data was recorded. The location of the melting endotherm, where one existed, was determined visually, and the heat of fusion determined from the weight normalized integral of the melting endotherm.
- The procedures of Example 1 were repeated except that 49 g of 1,2,3,3,3-pentafluoropropylene and 26 g of TFE were used and the autoclave was heated to 80° C. for ten hours. During the polymerization the pressure decreased from 465 psi to 445 psi. 8.6 g of dry polymer were obtained. A DSC curve obtained between ca. 0° C. and 300° C. exhibited a broad shallow endotherm with a heat of fusion of ca. 6 J/g indicating a small amount of crystallinity. The 19F NMR of the melted polymer (at 115° C.) showed four broad peaks which upon integration showed that the polymer contained 17.5 mole percent of 1,2,3,3,3-pentafluoropropylene.
- The polymer did not dissolve in hexafluorobenzene at room temperature. 100 mg of the polymer were suspended in 4 mL hexafluorobenzene (4 mL) and heated to 60° C. a clear solution was not obtained even on prolonged (4 hours) stirring.
-
FIG. 1 shows the DSC results obtained according to the method described above. A well defined endotherm was identified corresponding to a melting transition at 177.66° C., and a heat of fusion of ca 10 J/g. - The materials and procedures of Example 1 were replicated except that the ratio of 1,2,3,3,3-pentafluoropropylene to TFE was slightly higher to give a polymer containing 30 mol-% of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
-
FIG. 2 shows the DSC results obtained. No melting endotherm could be discerned. - The materials and procedures of Example 1 were replicated except that the ratio of 1,2,3,3,3-pentafluoropropylene to TFE was slightly higher to give a polymer containing 40 mol-% of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
-
FIG. 3 shows the DSC results obtained. A very small melting endotherm associated with a crystalline melting point of 83° C. might be an artifact. The associated heat of fusion was 0.7 J/g.
Claims (21)
1. A solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
2. The solution of claim 1 wherein the amorphous copolymer comprises 25 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
3. The solution of claim 2 wherein the amorphous copolymer comprises 30 to 45 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
4. The solution of claim 1 wherein the amorphous copolymer further comprises up to 10 mole percent of one or more additional monomer units derived from olefinic monomers.
5. The solution of claim 1 wherein the amorphous fluoropolymer concentration is 1% to 20% by weight of the total weight of the solution.
6. The solution of claim 5 wherein the amorphous fluoropolymer concentration is 5% to 15% by weight of the total weight of the solution.
7. The solution of claim 1 wherein the fluoroaromatic solvent is hexafluorobenzene.
8. A method for preparing a coated article, the method comprising providing an article having a surface; contacting the surface of the article with a solution comprising a fluoroaromatic solvent and an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene; and evaporating the solvent to produce a coated article.
9. The method of claim 8 wherein the amorphous copolymer comprises 25 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
10. The method of claim 9 wherein the amorphous copolymer comprises 30 to 45 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
11. The method of claim 8 wherein the amorphous copolymer further comprises up to 10 mole percent of one or more additional monomer units derived from olefinic monomers.
12. The method of claim 8 wherein the amorphous fluoropolymer concentration is 1% to 20% by weight of the total.
13. The solution of claim 12 wherein the amorphous fluoropolymer concentration is 5% to 15% by weight of the total.
14. The method of claim 8 wherein the fluoroaromatic solvent is hexafluorobenzene.
15. The method of claim 8 wherein contacting the surface is effected by use of a doctor blade on a flat surface.
16. The method of claim 8 wherein contacting the surface is effected by use of spray coating.
17. The method of claim 8 wherein contacting the surface is effected by dip-coating.
18. A coated article comprising an article having a surface and a coating disposed upon the surface, the coating comprising an amorphous copolymer comprising 50 to 80 mole percent of monomer units derived from tetrafluoroethylene and 20 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene, the coating being characterized by a thickness of ≦10 micrometers.
19. The coated article of claim 18 wherein the amorphous copolymer comprises 25 to 50 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
20. The coated article of claim 19 wherein the amorphous copolymer comprises 30 to 45 mole percent of monomer units derived from 1,2,3,3,3-pentafluoropropylene.
21. The coated article of claim 18 wherein the amorphous copolymer further comprises up to 10 mole percent of one or more additional monomer units derived from olefinic monomers.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| US20110172336A1 (en) * | 2008-10-16 | 2011-07-14 | Asahi Glass Company, Limited | Fluorocopolymer composition and its production process |
| WO2014049444A3 (en) * | 2012-09-27 | 2015-06-18 | 三井・デュポンフロロケミカル株式会社 | Amorphous fluorine-containing resin composition, and manufacturing method for thin film |
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| US6248823B1 (en) * | 1998-07-02 | 2001-06-19 | E. I. Du Pont De Nemours And Company | Solvents for amorphous fluoropolymers |
| US6646077B1 (en) * | 2002-07-11 | 2003-11-11 | Dupont Dow Elastomers Llc | Peroxide curable fluoroelastomers |
| US6767626B2 (en) * | 2000-05-15 | 2004-07-27 | E. I. Du Pont De Nemours And Company | Method for protection of stone with substantially amorphous fluoropolymers |
| US20050153124A1 (en) * | 2004-01-08 | 2005-07-14 | Xerox Corporation | Wear resistant fluoropolymer |
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- 2008-05-21 US US12/124,566 patent/US8153198B2/en not_active Expired - Fee Related
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3350373A (en) * | 1963-01-25 | 1967-10-31 | Montedison Spa | Copolymers from 1, 2, 3, 3, 3-pentafluoropropylene and tetrafluoroethylene and process for preparing same |
| US6248823B1 (en) * | 1998-07-02 | 2001-06-19 | E. I. Du Pont De Nemours And Company | Solvents for amorphous fluoropolymers |
| US6767626B2 (en) * | 2000-05-15 | 2004-07-27 | E. I. Du Pont De Nemours And Company | Method for protection of stone with substantially amorphous fluoropolymers |
| US6646077B1 (en) * | 2002-07-11 | 2003-11-11 | Dupont Dow Elastomers Llc | Peroxide curable fluoroelastomers |
| US20050153124A1 (en) * | 2004-01-08 | 2005-07-14 | Xerox Corporation | Wear resistant fluoropolymer |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20110172336A1 (en) * | 2008-10-16 | 2011-07-14 | Asahi Glass Company, Limited | Fluorocopolymer composition and its production process |
| US8952083B2 (en) * | 2008-10-16 | 2015-02-10 | Asahi Glass Company, Limited | Fluorocopolymer composition and its production process |
| WO2014049444A3 (en) * | 2012-09-27 | 2015-06-18 | 三井・デュポンフロロケミカル株式会社 | Amorphous fluorine-containing resin composition, and manufacturing method for thin film |
| US9862852B2 (en) | 2012-09-27 | 2018-01-09 | Dupont-Mitsui Fluorochemicals Co., Ltd. | Amorphous fluorine-containing resin composition and a manufacturing method of thin films |
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